Packaging machine and method

ABSTRACT

A packaging method and apparatus wherein each product is packaged by enveloping the product in flexible packaging material. A programmed microprocessor calculates the length of flexible packaging material needed to package the product based on the physical dimensions of the product, calculates the weight of the flexible packaging material needed, and calculates a total package weight as the sum of the weight of the product and the calculated weight of the flexible packaging material. A printer prints information specific to the product that is being packaged onto a label that is then affixed to the flexible packaging material prior to the product being packaged. The information can be a function of the package weight, and the calculated total package weight can be communicated from the microprocessor to the printer. Finally, the product is packaged in the flexible packaging material having the label already affixed thereto.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related to currently pending U.S. patent applicationSer. No. 10/237,507 filed on Sep. 9, 2002, the entire disclosure ofwhich is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a method and apparatus for packagingproducts for shipping.

Mail-order companies and other organizations that deliver products bymail or courier are continually striving to improve the efficiency ofthe processes of packaging products and getting them ready for shipment,which generally includes labeling (i.e., affixing a label on eachpackage indicating the address of the recipient), and franking (i.e.,putting the correct postage on each package). In many cases, even if theproducts are packaged by an automated packaging machine, the processesof labeling and franking are performed at least in part by hand.

For instance, many small- to medium-volume shippers still manually weigheach package after the packages are produced. A label is then printed,and a worker manually applies the label to the package. Not only is thisprocedure inefficient, but it has potential for errors, such as applyingthe wrong label to a package.

BRIEF SUMMARY OF THE INVENTION

The present invention addresses the above needs and achieves otheradvantages. In one aspect of the invention, there is provided apackaging method and apparatus that automates the process of packagingproducts and that labels the packages during the process of producingthe packages. In some embodiments, the weight of each package isautomatically determined so that no post-production weighing procedureis required.

A method in accordance with one embodiment of the invention is suitablefor packaging products of varying weights and physical dimensions forshipping, wherein each product is packaged by enveloping the product inflexible packaging material of predetermined width and predeterminedweight per unit area (or, equivalently, predetermined weight per unitlength). The method includes using a programmed microprocessor tocalculate the length of flexible packaging material needed to packagethe product, based on the physical dimensions of the product, and tocalculate the weight of the flexible packaging material needed topackage the product based on the length, the predetermined width, andthe predetermined weight per unit area of the flexible packagingmaterial. The microprocessor then calculates a total package weight asthe sum of the weight of the product and the calculated weight of theflexible packaging material.

The method further includes using a printer to print information onto alabel that is then affixed to the flexible packaging material, whereinthe label is specific to the product that is being packaged. In someembodiments, the information can be a function of the package weight(e.g., the information can include the amount of postage payable forshipping the package, which depends on package weight). Accordingly, thecalculated total package weight can be communicated from themicroprocessor to the printer. Finally, the product is packaged in theflexible packaging material having the label already affixed thereto.

In preferred embodiments, first and second rolls of the flexiblepackaging material are provided and an upper web is drawn from one ofthe rolls and a lower web is drawn from the other roll, each of theupper and lower webs being advanced by a web drive system. The productis disposed between the upper and lower webs and the webs with theproduct therebetween are advanced by the web drive system through a nipto adhere the webs to each other and envelop the product therebetween.The lower web upstream of the nip is generally horizontal for receivingthe product thereon.

The lower web upstream of the nip can be advanced over a scale forweighing the product. The scale determines the weight of the product andcommunicates the weight to the microprocessor. Alternatively, the weightof each product can be determined by scanning a product code on theproduct or on a packing slip associated with the product and consultinga database that includes information such as product weightcorresponding to each of various product codes stored in the database.

In one embodiment, the method includes the step of using a productlength detector to determine the length of the product disposed on thelower web. The microprocessor calculates the length of each of the upperand lower webs of flexible packaging material needed for packaging theproduct based in part on the length of the product. The length of webmaterial needed can also depend on the product height, which can beeither measured by a height detector or known in advance (e.g., byconsulting the database based on a scanned product code) and input tothe microprocessor.

When a scale is used for weighing products, the method can beimplemented in a batch mode wherein a first product of a batch ofidentical products is weighed by the scale and the weight is determinedfor the first product. The first product is then packaged as previouslydescribed. Thereafter, the weighing step is skipped and themicroprocessor uses the same weight for each subsequent product of thebatch.

In preferred embodiments of the invention, an automated label applicatoraffixes the label to the flexible packaging material. The methodincludes verifying whether the label was affixed by the labelapplicator, and the web drive system advances the webs and the productthrough the nip only after it has been verified that the label wasaffixed.

The invention in another aspect provides a packaging method andapparatus wherein an extendable and retractable infeed gate is disposedupstream of the nip through which the product is advanced between thewebs of flexible packaging material. The infeed gate is extended into ablocking position proximate the lower web so that a product to bepackaged can be placed onto the lower web and abutted against the infeedgate. In this manner, the leading edge of the product is positioned at aknown location along the longitudinal direction (i.e., the productlength direction) in which the product is advanced into the nip. Theinfeed gate thus facilitates automatic detection of the product lengthusing a product length detector. The infeed gate is then retracted toits unblocking position such that the webs and product can be advancedthrough the nip.

A packaging apparatus in accordance with another embodiment of theinvention, which facilitates labeling of the packaging material prior tothe packaging operation, comprises a pair of opposed rollers forming anip therebetween, a web guide system for guiding a pair of opposingupper and lower webs of flexible packaging material into the nip, aninfeed bed located upstream of the nip, the lower web being supported bythe infeed bed such that a product to be packaged can be placed onto thelower web on the infeed bed and advanced along with the lower web in alongitudinal direction into the nip, and a generally planar labelingsupport member spaced upstream of the nip. The web guide system includesupper web guides structured and arranged to guide the upper web totravel along a surface of the labeling support member such that theupper web is supported by the labeling support member and an uppersurface of the upper web is accessible for affixing an adhesive labelthereon. The affixing can be accomplished manually or by using anautomated label applicator.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a perspective view of a packaging machine in accordance withone embodiment of the invention;

FIG. 2 is a perspective view of a module frame supporting variousequipment in accordance with another embodiment of the invention;

FIG. 3 is a perspective view of a package, also showing a label affixedthereto;

FIG. 4 is a diagrammatic view of a packaging machine in accordance withan embodiment of the invention, showing the interconnections of variouscomponents of the machine;

FIG. 5 is a partial perspective view of a packaging machine inaccordance with an embodiment of the invention, showing operation of aninfeed gate;

FIG. 6 is a cross-sectional view along line 6-6 in FIG. 1;

FIG. 7A is a sectioned side view of an infeed gate assembly inaccordance with another embodiment of the invention, shown in a firstposition;

FIG. 7B shows the infeed gate in a second position;

FIG. 8 is a perspective view of the infeed gate of FIGS. 7A and 7B;

FIG. 9A is a sectioned side view of an infeed gate assembly inaccordance with yet another embodiment of the invention, shown in afirst position;

FIG. 9B shows the infeed gate in a second position; and

FIG. 10 is a diagrammatic illustration of a detector system fordetecting the leading edge of a product placed on the lower web on theinfeed bed.

DETAILED DESCRIPTION OF THE INVENTION

The present inventions now will be described more fully hereinafter withreference to the accompanying drawings, in which some but not allembodiments of the inventions are shown. Indeed, these inventions may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

A packaging apparatus 20 in accordance with one embodiment of theinvention is shown in FIG. 1. The apparatus 20 is of the dual-web typefor advancing a first or upper web 22 and a second or lower web 24 ingenerally parallel opposing relation with an object disposed between thewebs and sealing the webs together to capture the object therebetween.The apparatus includes a main frame having a base formed by a pluralityof spaced vertical support columns 26, 28, 30, on one side of alongitudinal axis of the apparatus, and a corresponding plurality ofspaced vertical support columns 26′, 28′, 30′ (column 30′ not visible inFIG. 1) on the opposite side of the longitudinal axis. Upper and lowerlongitudinal members 32 are rigidly connected between support columns 26and 28 and between support columns 28 and 30, and similar longitudinalmembers 32′ are rigidly connected between columns 26′ and 28′ andbetween columns 28′ and 30′. A lower transverse member 34 is rigidlyconnected between the support columns 26 and 26′, a lower transversemember 36 is rigidly connected between the support columns 28 and 28′,and a lower transverse member 38 is rigidly connected between thesupport columns 30 and 30′. A generally planar infeed bed 40 is rigidlyconnected between the longitudinal members 32, 32′. A lower longitudinalmember 42 is rigidly connected between the lower transverse members 36and 38.

The main frame also includes a superstructure that extends up from thebase and above the infeed bed 40. The superstructure is formed by upwardextensions of the support columns 26, 26′, 28, 28′, 30, and 30′. Anupper transverse member 44 is rigidly connected between the upper endsof the columns 26 and 26′, and an upper transverse member 46 is rigidlyconnected between the upper ends of the columns 30 and 30′. An upperlongitudinal member 48 is rigidly connected between the upper ends ofthe columns 26 and 30, and an upper longitudinal member 50 is rigidlyconnected between the upper ends of the columns 26′ and 30′.

Upstream columns 26 and 26′ support web mounts 52, 54 that respectivelysupport supply rolls of the webs 22, 24 in a rotatable manner. The upperweb 22 is drawn from its supply roll and advanced over a guide 56supported between the longitudinal members 48, 50, then over a guide 58supported between the longitudinal members 48, 50 and spacedlongitudinally downstream from the first guide 56, and then downward forfurther handling as described in detail below. The lower web 24 is drawnfrom its supply roll and advanced under a lower guide 60 supportedbetween columns 28, 28′, then over an upper guide 62 supported betweencolumns 28, 28′, then onto the upper surface of the infeed bed 40. Theinfeed bed supports a pair of web edge guides 64, 66 that extendparallel to the longitudinal axis of the machine and are spaced apart bya distance about equal to the width of the lower web 24. The edge guidescapture the opposite edges of the web 24 between the infeed bed and theguides and thereby hold the lower web flat on the infeed bed andsubstantially prevent transverse movement of the web, while allowing theweb to freely move in the longitudinal direction. A product P to bepackaged is placed upon the lower web 24 on the infeed bed, as furtherdescribed below.

With reference to FIGS. 1, 4, and 6, the apparatus includes a pair ofrollers 70, 72 that are rotatably mounted in the main frame at adownstream end thereof. The rollers 70, 72 form a nip through which thewebs 22, 24 are advanced with the product P disposed therebetween.Advantageously, one or both of the rollers 70, 72 comprises aresiliently deformable material at least over a medial portion of theroller's length, such that the passage of the product through the nipdeforms the roller(s) and the restoring force of the resilientlydeformable material presses the webs 22, 24 toward each other so thatthe web conform closely to the product. The webs advantageously havecold seal or cohesive material on their facing surfaces such that theapplication of pressure by the rollers 70, 72 causes the webs to adhereto each other but not to the product. The end portions of each of therollers 70, 72 advantageously comprise a generally non-deformablematerial for firmly gripping the opposite edge portions of the webs 22,24, and the rollers advantageously are rotatably driven for advancingthe webs through the apparatus, thus comprising a web drive system.Alternatively, a separate web drive system can be employed if desired.

With reference to FIGS. 1 and 4, at a downstream end of the infeed bed40, an upper web support plate 74 is mounted between a pair of spacedend plates 76, forming a housing that rests atop the base of the mainframe. This housing preferably is pivotable relative to the main frameabout hinges (not shown) located at the upper downstream corner of thehousing, for access to internal parts of the machine when required formaintenance and the like. The upper web support plate 74 is spacedvertically above the level of the infeed bed. The upper web is advancedbeneath a pair of longitudinally spaced web guides 78, 80 supported atopthe end plates 76, such that the upper web passes along the uppersurface of the support plate 74. As further described below, the supportplate 74 provides support for the upper web 22 so that an adhesive labelcan be affixed onto the web either by hand or, in some embodiments asdescribed below, by a labeling unit.

The apparatus 20 in the illustrated embodiment also includes a moduleframe 82, best seen in FIG. 2. The module frame comprises a stand-alonemodule that is configured to support various components that tend to bespecific to a particular user of the packaging apparatus, and that isconfigured to releasably dock with the main frame of the apparatus sothat the components are positioned properly for operation during thepackaging process. The module frame comprises a base formed by a pair ofspaced longitudinal members 84, 86 each of which has wheels 88 such ascaster wheels or the like for rolling the module frame along a floor,and a transverse member 90 rigidly connected between the longitudinalmembers 84, 86. A vertical support column 92 extends upwardly from thebase. A longitudinal support member 94 is rigidly connected to thecolumn 92 in cantilever fashion and supports a generally horizontalplatform 96. The upper end portion of the support column 92 supports afixture 98 configured to mount a labeling unit 100. A customer terminal102, comprising a microprocessor and memory (e.g., a personal computer),is mounted on the transverse member 90 of the module frame. A visualdisplay monitor 104, a keyboard 106, and a mouse 108 are supported bythe platform 96 and are connected to the customer terminal 102. Aproduct scanner 110 is also supported by the platform 96. Thesecomponents and their operation are further described below.

The module frame 82 includes releasable fastening devices 112 mounted onthe longitudinal base member 84. The fastening devices 112 areconfigured to releasably engage corresponding fastening devices 114(FIG. 1) on the longitudinal member 42 of the main frame of theapparatus so as to dock the module frame with the main frame.

The labeling unit 100 comprises a printer 116 operable to print onadhesive labels that are preferably in the form of a continuous web ofrelease liner material with the labels releasably adhered to the linerand spaced along its length direction. A roll 118 of the adhesive labelsis mounted on the module frame adjacent the labeling unit. The label webis advanced through the printer, the printer prints on each label, andthen the label is separated from the release liner for application tothe upper web 22. The labeling unit includes an automated labelapplicator 120 that receives the label from the printer. A sensor 122(FIG. 4) detects when a label has been received by the applicator, asfurther described below. The label applicator includes a suitablemechanism for holding onto the upper, non-adhesive side of the label,such as a vacuum-operated tamp head 124. The tamp head 124 is movable bya suitable pneumatic cylinder or the like between an upper position anda lower position; in the lower position, the adhesive label held by thetamp head is pressed against the upper web 22 supported on the supportplate 74, thereby affixing the label to the web. There are a variety ofcommercially available labeling units that can be used in the practiceof the invention, and the invention is not limited to any particulartype. A suitable labeling unit is the Model 250 print and apply labelingsystem available from RSI ID Technologies of Chula Vista, Calif.; thesystem includes a Zebra thermal-transfer printer. Other types ofprinting devices can be used, including ink jet, laserjet, and the like.Furthermore, it is within the scope of the invention to print directlyonto the flexible packaging material rather than onto a separate label.

With primary reference to FIG. 4, after the upper web 22 has had a labelaffixed to it, the upper web and lower web are advanced by the web drivesystem to pass through the nip between the rollers 70, 72, along withthe product P supported on the lower web 24. The distance traveled bythe upper web between the label application station and the nip isdesigned in relation to the distance traveled by the product from itsinitial location on the infeed bed to the nip so that the label on theupper web is generally centered on a package formed to envelope theproduct. After the product passes through the nip, a cutoff device 130severs the web material at a location spaced downstream from thetrailing edge of the product to produce a completed package. A packageoutfeed conveyor 132 receives the package and conveys it to anotherlocation such as into a bin (not shown).

With reference to FIGS. 4 and 5, the apparatus 20 advantageouslyincludes an infeed gate 140 suitably mounted (such as below the upperweb support plate 74) in a position upstream of the nip defined by therollers 70, 72. The infeed gate is connected to an actuator 142, such asa pneumatic cylinder or the like, operable to move the infeed gatebetween a blocking position wherein the lower edge of the gate abuts ornearly abuts the lower web 24 on the infeed bed 40 and an unblockingposition wherein the lower edge of the gate is spaced above the lowerweb by a distance exceeding a maximum height of the products to bepackaged such that the products can pass beneath the gate. Thus, when apackage is to be formed, the infeed gate is lowered to the blockingposition and the product is placed on the lower web with the leadingedge of the product abutting the gate. This ensures that the leadingedge of the product is in a consistent, repeatable location with respectto the nip.

With reference to FIGS. 1 and 4, the apparatus 20 also includes aproduct length detector 150 for measuring the length of a productdisposed on the lower web 24 on the infeed bed 40. The product lengthdetector can comprise various types of devices, including but notlimited to an optical distance-measuring device such as a laserdistance-measuring device. The product length detector is preferablymounted adjacent an upstream end of the infeed bed 40 and is positionedand aimed at the trailing edge of the product disposed on the lower web.By measuring the distance from the detector to the trailing edge, andwith knowledge of the distance from the detector to the leading edge(e.g., when the infeed gate 140 is employed and the leading edge isabutted against the gate), the length of the product between the leadingand trailing edges can be determined.

With reference to FIG. 4, the apparatus 20 in some embodiments caninclude a scale 154 embedded in the infeed bed 40 in such a manner thatthe lower web 24 passes over the scale and the weight of a productdisposed on the lower web is entirely supported by the scale. Forexample, the infeed bed can have an aperture therein and the scale canbe mounted beneath the aperture such that the upper surface of the scaleis flush with the upper surface of the infeed bed. The total weightsupported by the scale comprises the product plus a portion of the lowerweb; accordingly, a tare measurement of the lower web alone can besubtracted from the total weight to determine the product weight. Theproduct weight is one component of the total weight of a packageenclosing the product. The total package weight is determined in amanner described below.

As noted, the apparatus includes a product scanner 110. The productscanner is positioned above the infeed bed near the infeed gate 140 sothat a product placed on the lower web against the gate can be scannedto detect a product code on the product or on an item that is packagedalong with the product, such as a packing slip. The product code can bein the form of a bar code the encodes a universal product code or thelike. The scanner can comprise a bar code reader. Based on the productcode, information about the identity of the product and itscharacteristics (e.g., product weight, product length, product height,etc.) and other information associated with the product can bedetermined. Such information can be stored in the memory of the customerterminal 102, for instance.

The apparatus 20 includes a controller 160 comprising a microprocessorand memory (e.g., a personal computer or the like). The controller 160is programmed to control the various motors and actuators of theapparatus 20 that effect movement of the moving parts such that themovements are properly synchronized with respect to one another and sothat packages are properly made and labeled. FIG. 4 shows theinterconnections between the controller 160 and certain components ofthe apparatus; in addition to the connections shown in FIG. 4, it willbe understood that the controller 160 is also connected to the motor 162that drives the nip rollers 70, 72, to the cutoff device 130, to themotor 164 that drives the outfeed conveyor 132, and to the actuator 142for the infeed gate 140. As depicted in FIG. 4, the controller 160 isconnected to the product length detector 150 and receives a signaltherefrom. The detector 150 can be calibrated so that its signal isdirectly indicative of the product length; alternatively, the signal canbe indicative of the distance from the detector to the trailing edge ofthe product, and the microprocessor of the controller 160 can beprogrammed to calculate the product length by subtracting that distancefrom a predetermined distance between the detector and the infeed gate140 stored in the memory of the controller.

The controller 160 is also connected to the product scanner 110 forreceiving a signal therefrom indicative of the product code read by thescanner. The memory of the controller 160 can store a database thatincludes product information correlated with product codes, so thatbased on the product code indicated by the signal from the scanner 110,information about the product can be retrieved from the database. Theinformation can include, for example, the height of the product. Theproduct height is important because the length of the packaging materialwebs 22, 24 required for packaging a product depends not only on theproduct length but also on the product height. In particular, the lengthof the fin (i.e., the portion of web material that extends upstream ofthe product's leading edge and the portion that extends downstream ofthe product's trailing edge) advantageously depends on product height;for instance, the fin length can be a multiple of the product heightsuch that the greater the product height, the greater the fin length.Thus, product height must be known. This can be accomplished either bystoring the predetermined product height in the database of thecontroller 160 and accessing it based on the scanned product code, or byusing a product height detector. As an example, the product heightdetector can be incorporated into or mounted alongside the scanner 110,or in another suitable location.

The microprocessor of the controller 160 advantageously is programmed tocalculate the length of the webs 22, 24 needed for packaging the productscanned by the scanner 110. The required length, as noted, depends onthe product length and product height. The microprocessor is alsoprogrammed to calculate the weight of the required length of the webs22, 24 based on the web length and a predetermined weight per unitlength of the web material stored in the memory of the controller; thus,the weight of each web is equal to the length multiplied by the weightper unit length. Alternatively, the weight of each web can be calculatedby multiplying the length by a predetermined weight per unit area orbasis weight and multiplying that product by a predetermined width ofthe web material.

The controller 160 is connected to the scale 154, when a scale ispresent. The scale provides a signal indicative of the weight exerted onthe scale and communicates the signal to the controller 160. Aspreviously noted, the scale advantageously is tared to effectivelysubtract the weight of the lower web (and taring preferably is performedbefore each product is weighed), such that the signal from the scale isdirectly indicative of the product weight. The microprocessor of thecontroller calculates the total package weight as the sum of the productand web material weights.

The controller 160 is also connected to the labeling unit 100 forcontrolling its operation. As previously described, the labeling unitincludes a sensor 122 for detecting when a label has been received atthe tamp head 124 of the label applicator 120. The signal from thesensor 122 is received by the controller 160. The microprocessor of thecontroller is programmed so that the web drive system is activated toadvance the webs and product through the nip if and only if the sensor122 confirms that a label was received at the tamp head, which gives apositive confirmation (once the tamp head is lowered against the upperweb) that a label has been affixed to the upper web 22. Preferably, thelabel is printed and affixed only if the product code has beensuccessfully scanned by the scanner 110. Thus, the invention ensuresthat packages are made only if a good scan has been accomplished and alabel has been printed and affixed.

The operation of the apparatus 20 is now explained with primaryreference to FIGS. 1 and 4. Rolls of upper and lower webs 22, 24 aremounted in the web mounts 52, 54, respectively. The upper web 22 isthreaded through the machine by advancing the web over the guides 56, 58and then downward and under the guides 78, 80, and then through the nipbetween rollers 70, 72. The lower web 24 is threaded by advancing theweb under guide 60, over guide 62, through the web edge guides 64, 66and through the nip. To begin a packaging sequence, a product P isplaced on the lower web 24 against the infeed gate 140, which isnormally down in its blocking position unless the controller commandsits actuator to raise the gate. A cycle start button (not shown) ispressed, which causes the controller 160 to execute a series ofoperations as follows: The controller 160 causes the product scanner 110to scan the product code, and the signal from the scanner is sent to thecustomer terminal 102, which, based on the product code, accesses itsdatabase and retrieves information about the scanned product that willbe used, among other things, for generating information to be printed ona label. The controller 160 also receives feedback from the scanner 110to confirm the product was scanned. Next, the scale 154 is tared and theproduct is weighed, and the product weight is stored in the memory ofthe controller 160. The product length detector 150 measures thedistance to the product's trailing edge and the microprocessor of thecontroller 160 calculates the product length based on that measureddistance and the known distance to the infeed gate 140 where theproduct's leading edge is located. The microprocessor then calculatesthe length of the webs 22, 24 required for the package based on theproduct length, and advantageously also based on the product height,which can be either measured with a height detector or stored in adatabase in the customer's terminal (or, alternatively, in the memory ofthe controller 160). Based on the web length, the microprocessor of thecontroller 160 then calculates the material weight using a formula suchas web length multiplied by weight per unit length or the like. Thetotal package weight is then calculated as the sum of the product weightand the web material weight, and the package weight is stored in thememory of the controller 160 and/or is communicated to the customerterminal 102 where it is stored.

The customer terminal 102 then can generate information to be printed ona packing slip for packaging along with the product, and thatinformation can be sent to a packing slip printer (not shown), ifdesired. The customer terminal 102 also sends the label information tothe printer 116 of the labeling unit 100, which prints a label and sendsthe label to the label applicator 120. The label sensor 122 monitors todetect when the label is received by the tamp head 124 of theapplicator, and the applicator then affixes the label onto the upper web24 on the support plate 74. Finally, the controller 160 causes the webdrive system motor 162 to drive the rollers 70, 72 to advance the webs22, 24 and the product P through the nip to produce a package 200, whichis cut off by the cutoff device 130 and conveyed by the outfeed conveyor132 to the machine discharge. The process generally as described aboveis repeated for each subsequent package. The microprocessor of thecontroller 160 is programmed to alternately advance the webs by an indexdistance (i.e., the required length of the webs for packaging eachproduct) and bring the webs to a stop, with the index distance beingdetermined by the controller for each product based on the length of theproduct indicated by the product length detector, as previouslydescribed.

FIG. 3 depicts a package 200 produced in accordance with the invention.The product P is enclosed between the upper web 22 and lower web 24,which are sealed to each other at marginal regions of the websurrounding the product. A label L is affixed to the upper web 22. Asshown, the label is printed with text and/or symbols embodyinginformation such as the recipient's name and address, sender's name andaddress, postal routing information, and optionally printing thatevidences that the amount of postage payable for shipping the packagehas been paid.

An alternative infeed gate assembly in accordance with anotherembodiment of the invention is depicted in FIGS. 7A, 7B, and 8. Theinfeed gate assembly includes an infeed gate 240 pivotally connected atits upper edge to a member 241 of the structure that includes the upperweb support plate 74. An actuator 242 such as a pneumatic cylinder orthe like is connected between the structure and the infeed gate forcausing pivotal movement of the gate between a first or blockingposition shown in FIG. 7A and a second or unblocking position shown inFIG. 7B. The infeed gate can be positioned at different angularorientations for products of different heights so that a fin length(i.e., the length of packaging material that extends forward of theleading edge of the product on a finished package) can be varied asdesired. As seen in FIG. 7A, even for a single oblique angularorientation of the infeed gate 240, the fin length will vary fordifferent height products. In particular, the thicker or higher productP will have a greater fin length than the thinner product because theleading edge of the thicker product will be located farther upstreamfrom the package cutoff device (not shown) compared to the thinnerproduct. In general, it is desirable for the fin length to be greaterfor thicker products. By varying the angular orientation of the infeedgate in its blocking position as a function of product height, greatercontrol over the fin length can be achieved, if desired. A sensor 244can be located downstream of the gate for detecting the product as it isconveyed past the gate. The gate can include a slot 246 at its loweredge to prevent blocking the sensor's light of sight when the gate israised as shown in FIG. 7B. The sensor signal can be used for variouspurposes. For example, once the product clears the sensor location, thegate can be lowered again in preparation for the next product.

Still another embodiment of an infeed gate assembly is shown in FIGS. 9Aand 9B. The infeed gate assembly includes an infeed gate 340 that ismounted to the structure that includes the upper web support plate 74.In particular, the structure defines guide tracks 348 along each of theopposite side edges of the gate, the tracks extending in an inclineddirection upwardly and downstream. An actuator 342 is connected betweenthe structure and the gate for moving the gate between a lowered orblocking position (FIG. 9A) and a raised or unblocking position (FIG.9B). The advantage of this infeed gate assembly is that as the gate israised, it is also moved downstream away from the product. There is thusa substantially reduced chance that the gate will tend to lift theproduct along with the gate and thereby inadvertently shift theproduct's position on the lower web.

The packaging machine and method described above can be modified invarious other ways within the scope of the present invention. Forexample, the infeed gate 140 can be omitted and instead, a detectorsystem can be used for detecting the leading edge of the product toensure that the leading edge is in the proper location before thepackaging sequence is initiated. As an illustrative example, FIG. 10 isa diagrammatic illustration looking down on the lower web 24 on theinfeed bed of the machine. To guide an operator in placing a product Pon the lower web in the proper location with respect to the downstreamnip rollers so that the label affixed to the upper web and the productare correctly located with respect to each other, a detector system 180can be used. The detector system can comprise various types andarrangements of detectors operable to detect the leading edge of theproduct. The illustrated detector system comprises a pair of beamemitters 182 a and 184 a located adjacent one longitudinal edge of thelower web 24 and spaced a slight distance apart in the longitudinaldirection, and a corresponding pair of beam receivers 182 b and 184 blocated adjacent the opposite longitudinal edge of the web directlyacross from the emitters. The emitter 182 a emits a beam of light in theinvisible or visible spectrum, and as long as there is no product on theweb blocking the beam's path, the receiver 182 b receives the beam andproduces a signal. Likewise, the receiver 184 b receives the beamemitted by the emitter 184 a as long as the product is not blocking thebeam and produces a signal. When a product is placed on the lower webupstream of the beams and is slid downstream, at some point, as shown inFIG. 7, the product's leading edge block the beam of the first emitter182 a but does not block the beam of the second emitter 184 a; thiscauses the first receiver 182 b to produce no signal (or a signal of adifferent character), while the second receiver 184 b produces a signal(or a signal of unchanged character). When this condition is met, it isknown that the product's leading edge is in the correct location. If theproduct is too far downstream and blocks both beams, or is too farupstream and blocks neither beam, it is known based on the receiversignals that the product location is incorrect. The tolerance on leadingedge location is a function of the longitudinal spacing of theemitters/receivers, and can be selected as desired. A “go” or “ready”light 186 connected to the detector system is illuminated only when theproduct is correctly located. When the operator gets the “go” light, theproduct length can be detected as previously described, and thepackaging sequence can proceed.

In accordance with another embodiment of the invention, the detectedproduct length is used in order to center a label on a package. Moreparticularly, in this embodiment, the label applicator 120 tamps thelabel onto the upper web 22 while the upper web is being advanced towardthe nip (i.e., “on-the-fly” tamping). The timing of the tamping iscontrolled by the controller 160, based on the product length, so thatthe label is substantially centered on the resulting package in thelongitudinal direction. The objective is to have the longitudinalmidpoint of the label and the longitudinal midpoint of the productsubstantially coincide in the longitudinal direction.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A method for packaging products of varying weights and physicaldimensions using flexible packaging material of predetermined width andpredetermined weight per unit area, comprising the steps of: providingto a programmed microprocessor the weight and physical dimensions of aproduct to be packaged; using the microprocessor to calculate the lengthof the flexible packaging material needed to package the product, basedon the physical dimensions of the product; using the microprocessor tocalculate the weight of the flexible packaging material needed topackage the product based on the length, the predetermined width, andthe predetermined weight per unit area of the flexible packagingmaterial, and to then calculate a total package weight as the sum of theweight of the product and the calculated weight of the flexiblepackaging material; using a printer to print information onto a label,said information comprising information that is specific to the product;and enveloping the product in the flexible packaging material to form apackage comprising the label and an amount of the flexible packagingmaterial corresponding to the calculated length and weight.
 2. Themethod of claim 1, further comprising communicating the calculated totalpackage weight from the microprocessor to the printer, and wherein theinformation printed on the label is a function of the total packageweight.
 3. The method of claim 1, wherein first and second rolls of theflexible packaging material are provided and an upper web is drawn fromone of the rolls and a lower web is drawn from the other roll, each ofthe upper and lower webs being advanced by a web drive system, andwherein the product is disposed between the upper and lower webs and thewebs with the product therebetween are advanced by the web drive systemthrough a nip to adhere the webs to each other and envelop the producttherebetween.
 4. The method of claim 3, wherein the lower web upstreamof the nip is generally horizontal for receiving the product thereon. 5.The method of claim 4, further comprising the step of scanning a productcode associated with the product disposed on the horizontal lower webupstream of the nip.
 6. The method of claim 5, further comprising thesteps of communicating the scanned product code to a customer terminalhaving a memory that stores data relating product codes of variousproducts to information about said products.
 7. The method of claim 6,wherein the customer terminal generates information to be printed on alabel and communicates said information to the printer, and the printerprints said information on the label for application to one of the webs.8. The method of claim 4, wherein the lower web upstream of the nip isadvanced over a scale for weighing the product, and the scale determinesthe weight of the product and communicates the weight to themicroprocessor.
 9. The method of claim 8, wherein a first product of abatch of identical products is weighed by the scale and the weight isdetermined for the first product, and wherein the microprocessor usesthe same weight for each subsequent product of the batch withoutweighing each subsequent product.
 10. The method of claim 3, furthercomprising the steps of using an automated label applicator to affix thelabel to the flexible packaging material, and verifying whether thelabel was affixed by the label applicator, and wherein the web drivesystem advances the webs and the product through the nip only after ithas been verified that the label was affixed.
 11. The method of claim 1,further comprising the step of using a product length detector todetermine the length of the product disposed on the lower web, andwherein the microprocessor calculates the length of each of the upperand lower webs of flexible packaging material needed for packaging theproduct based in part on said length of the product.
 12. The method ofclaim 1, further comprising the step of using a product height detectorto determine the height of the product disposed on the lower web, andwherein the microprocessor calculates the length of each of the upperand lower webs of flexible packaging material needed for packaging theproduct based in part on said height of the product.
 13. The method ofclaim 1, further comprising the steps of using a product length detectorto determine the length of the product disposed on the lower web andusing a product height detector to determine the height of the productdisposed on the lower web, and wherein the microprocessor calculates thelength of flexible packaging material of each of the upper and lowerwebs needed for packaging the product based on said length and saidheight of the product.
 14. The method of claim 1, wherein themicroprocessor calculates the length of flexible packaging material ofeach of the upper and lower webs needed for packaging the product basedon the length and the height of the product disposed on the lower web,and calculates the weight of the flexible packaging material as the sumof the weight of the upper web and the weight of the lower web.
 15. Themethod of claim 1, further comprising the step of using a cutting deviceto sever the flexible packaging material along a cut line locatedupstream of the product after passage of the product through the nip.16. The method of claim 15, wherein the cutting device is controlledsuch that the cut line is longitudinally spaced from the product by adistance that is a function of a height of the product, said distancebeing calculated by the microprocessor, and wherein the microprocessortakes said distance into account in calculating the length of theflexible packaging material needed for packaging the product.
 17. Apackaging machine for packaging products of varying weights and physicaldimensions using flexible packaging material of predetermined weight perunit area, the packaging machine comprising: one or more roll mountsstructured and arranged to rotatably support a pair of rolls of theflexible packaging material; a web drive and guide system operable toadvance an upper web from one of the pair of rolls and a lower web fromthe other roll of the pair of rolls, and to advance the upper and lowerwebs to a packaging station; an infeed bed located upstream of thepackaging station, the lower web being supported by the infeed bed suchthat a product to be packaged can be placed onto the lower web on theinfeed bed; the packaging station comprising a pair of rollers forming anip through which the upper and lower webs with the product disposedtherebetween are advanced in a longitudinal direction such that the websare adhered to each other and envelop the product; a controllercomprising a microprocessor programmed to determine the weight of theflexible packaging material needed to package the product based on knowncharacteristics of the product, and to then calculate a total packageweight as the sum of the weight of the product and the weight of theflexible packaging material; and a labeling unit disposed upstream ofthe packaging station, the labeling unit comprising a printer forprinting information specific to the product onto a label and anautomated label applicator for affixing the label to one of the upperand lower webs prior to the product being advanced through the nip. 18.The packaging machine of claim 17, the labeling unit being connected tothe microprocessor for receiving the calculated total package weight andfor printing information onto the label, said information being afunction of at least the total package weight.
 19. The packaging machineof claim 17, further comprising a product length detector operable todetermine the length of the product disposed on the lower web, andwherein the microprocessor is programmed to calculate the length of eachof the upper and lower webs of flexible packaging material needed forpackaging the product based in part on said length of the product. 20.The packaging machine of claim 19, wherein the controller is programmedto coordinate the advancing of the webs by the web drive and guidesystem and the affixing of the label on said one of the webs by thelabel applicator, based on the length of the product, so that the labelis substantially centered on a package in the longitudinal direction.21. The packaging machine of claim 17, further comprising a productheight detector operable to determine the height of the product disposedon the lower web, and wherein the microprocessor is programmed tocalculate the length of each of the upper and lower webs of flexiblepackaging material needed for packaging the product based in part onsaid height of the product.
 22. The packaging machine of claim 17,further comprising a product length detector operable to determine thelength of the product disposed on the lower web, and a product heightdetector operable to determine the height of the product disposed on thelower web, and wherein the microprocessor is programmed to calculate thelength of each of the upper and lower webs of flexible packagingmaterial needed for packaging the product based on said length and saidheight of the product.
 23. The packaging machine of claim 17, whereinthe cutoff station comprises a cuffing device operable to sever theflexible packaging material along a cut line located upstream of theproduct after passage of the product through the nip.
 24. The packagingmachine of claim 23, wherein the controller is connected with thecutting device and is programmed to control the cuffing device such thatthe cut line is longitudinally spaced from the product by a distancethat is a function of a height of the product, said distance beingcalculated by the microprocessor, and wherein the microprocessor isprogrammed to take said distance into account in calculating the lengthof the flexible packaging material needed for packaging the product. 25.The packaging machine of claim 17, wherein the controller is connectedwith a sensor associated with the automated label applicator, the sensorbeing operable to detect when a label has been received and affixed tothe flexible packaging material and to send a signal to the controllerindicating the label was received and affixed, the controller beingprogrammed to verify whether the label was affixed by the labelapplicator, and wherein the controller is connected with the web drivesystem and is programmed to control the web drive system to advance thewebs and the product through the nip only after the controller hasverified that the label was affixed.
 26. The packaging machine of claim17, further comprising a scanner operable to scan a product codeassociated with the product disposed on the lower web, the scanner beingadapted to be connected to a customer terminal having a memory thatstores data relating product codes of various products to informationabout said products.
 27. The packaging machine of claim 17, furthercomprising a scale located beneath the lower web for weighing theproduct disposed on the lower web, the scale being connected with thecontroller, wherein the scale determines the weight of the product andcommunicates the weight to the controller.
 28. The packaging machine ofclaim 27, wherein the controller is programmed to operate the machine ineither a batch mode or a non-batch mode, wherein in the batch mode afirst product of a batch of identical products is weighed by the scaleand the weight is determined for the first product and communicated tothe controller, and wherein the controller uses the same weight for eachsubsequent product of the batch without weighing each subsequentproduct.
 29. The packaging machine of claim 17, wherein the machinecomprises a main frame supporting the roll mount, the infeed bed, theweb drive and guide system, the packaging station, and the controller,and a module frame supporting equipment that comprises at least thelabeling unit, the module frame and the main frame being configured toreleasably dock the module frame with the main frame such that themodule frame and the equipment supported thereby may be removed from themachine.
 30. The packaging machine of claim 29, wherein the module frameis wheeled for rolling the module frame along a floor.
 31. The packagingmachine of claim 29, wherein the module frame further supports acustomer terminal comprising a computer processor and a visual displaymonitor and an input device connected with the computer processor.
 32. Apackaging machine for packaging products of varying lengths forshipping, wherein each product is packaged by enveloping the product inflexible packaging material, the packaging machine comprising: one ormore roll mounts structured and arranged to rotatably support a pair ofrolls of the flexible packaging material; an infeed bed, a lower webbeing drawn from one of the rolls of flexible packaging material andbeing supported by the infeed bed such that a product to be packaged canbe placed onto the lower web on the infeed bed; a packaging stationlocated downstream of the infeed bed and comprising a pair of rollersforming a nip, an upper web being drawn from the other roll of flexiblepackaging material and the upper and lower webs being advanced throughthe nip with the product disposed therebetween, such that the webs areadhered to each other and envelop the product, wherein the rollers aredriven by a motor to advance the webs through the nip; a product lengthdetector operable to measure a length of the product placed on the lowerweb; and a controller connected to the motor and to the product lengthdetector, the controller being programmed to alternately advance thewebs by an index distance and bring the webs to a stop, with the indexdistance being determined by the controller for each product based onthe length of the product indicated by the product length detector. 33.The packaging machine of claim 32, further comprising an infeed gatedisposed between the infeed bed and the nip, the infeed gate beingmovable between a blocking position adjacent the lower web such that theinfeed gate blocks passage of a product into the nip, and an unblockingposition spaced from the lower web such that the infeed gate allowspassage of a product into the nip.
 34. The packaging machine of claim33, wherein the product length detector is structured and arranged tomeasure a distance from the product length detector to a trailing edgeof the product located on the lower web, in a longitudinal directionalong which the product moves into the nip, the infeed gate beingpositioned such that a leading edge of the product is abutted againstthe infeed gate and thus at a known location in the longitudinaldirection, whereby the length of the product can be deduced from saiddistance.